U.S. patent application number 14/114981 was filed with the patent office on 2014-03-20 for panel composite body, display device and panel composite body manufacturing method.
This patent application is currently assigned to SHARP KABUSHIKI KAISHA. The applicant listed for this patent is Nobuhiro Nakata, Masataka Ohyama, Kenichiroh Tsuchida. Invention is credited to Nobuhiro Nakata, Masataka Ohyama, Kenichiroh Tsuchida.
Application Number | 20140078444 14/114981 |
Document ID | / |
Family ID | 47139167 |
Filed Date | 2014-03-20 |
United States Patent
Application |
20140078444 |
Kind Code |
A1 |
Tsuchida; Kenichiroh ; et
al. |
March 20, 2014 |
PANEL COMPOSITE BODY, DISPLAY DEVICE AND PANEL COMPOSITE BODY
MANUFACTURING METHOD
Abstract
This panel composite body 1 according to the present invention
is provided with: a main panel 11 that has a large first substrate
111 and a small second substrate 112, the edge portion 111a of the
large substrate 111 protruding further outwards than the edge
portion 112a of the small substrate 112, and that has a polarizing
plate 115 arranged on the outer surface 112c side of the second
substrate so as to fit on the plate surface of the second substrate
112; a plate member 12 that, protruding further outwards than the
edge portion 112a of the second substrate 112, sandwiches the
polarizing plate 115 together with the second substrate 112; and an
adhesive layer 21 that, bonding the main panel 11 and the plate
member 12, is disposed between the polarizing plate 115 and the
plate member 12 and, so as to cover the edge portion of the
polarizing plate 115, between the second substrate 112 and the
plate member 12.
Inventors: |
Tsuchida; Kenichiroh;
(Osaka, JP) ; Nakata; Nobuhiro; (Osaka, JP)
; Ohyama; Masataka; (Osaka, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tsuchida; Kenichiroh
Nakata; Nobuhiro
Ohyama; Masataka |
Osaka
Osaka
Osaka |
|
JP
JP
JP |
|
|
Assignee: |
SHARP KABUSHIKI KAISHA
Osaka
JP
|
Family ID: |
47139167 |
Appl. No.: |
14/114981 |
Filed: |
May 2, 2012 |
PCT Filed: |
May 2, 2012 |
PCT NO: |
PCT/JP2012/061587 |
371 Date: |
October 31, 2013 |
Current U.S.
Class: |
349/58 |
Current CPC
Class: |
G02F 1/133308 20130101;
G02F 2201/503 20130101; G02F 1/13338 20130101; G02F 1/133528
20130101; G02F 2202/28 20130101; G02F 1/13471 20130101 |
Class at
Publication: |
349/58 |
International
Class: |
G02F 1/1333 20060101
G02F001/1333; G02F 1/1335 20060101 G02F001/1335 |
Foreign Application Data
Date |
Code |
Application Number |
May 9, 2011 |
JP |
2011-104221 |
Claims
1. A panel composite body, comprising: a main panel having: a first
substrate and a second substrate that is smaller than the first
substrate, the first substrate and the second substrate forming a
pair of substrates bonded together such that respective inner
surfaces thereof face each other, an edge portion of the first
substrate protruding further out than an edge portion of the second
substrate; and a polarizing plate disposed on an outer surface of
the second substrate so as to fit within the outer surface of the
second substrate in a plan view; an auxiliary panel sandwiching the
polarizing plate with the second substrate, the auxiliary panel
having a plate member protruding further out than the edge portion
of the second substrate; and an adhesive layer bonding together the
main panel and the auxiliary panel, the adhesive layer being
disposed between the polarizing plate and the auxiliary panel and
between the second substrate and the auxiliary panel so as to cover
a periphery of the polarizing plate.
2. The panel composite body according to claim 1, wherein the
auxiliary panel further includes an opposite plate member bonded to
the plate member so as to face the plate member, the opposite plate
member being disposed between the plate member and the polarizing
plate.
3. The panel composite body according to claim 2, wherein the
auxiliary panel has a third substrate as the opposite plate member
and a fourth substrate that is larger than the third substrate as
the plate member forming a pair of substrates bonded together such
that respective inner surfaces thereof face each other, in which an
edge portion of the fourth substrate protrudes further out than an
edge portion of the third substrate, the edge portion of the fourth
substrate protruding further out than at least the edge portion of
the second substrate, an inner surface at the edge portion of the
fourth substrate facing an inner surface at the edge portion of the
first substrate, the polarizing plate being sandwiched between the
third substrate and the second substrate, and wherein the adhesive
layer bonds together the main panel and the auxiliary panel, the
adhesive layer being disposed between the polarizing plate and the
third substrate and between the second substrate and the third
substrate so as to cover a periphery of the polarizing plate.
4. A panel composite body, comprising: a main panel having a pair
of a first substrate and a second substrate bonded together such
that respective inner surfaces thereof face each other, and a
polarizing plate disposed on an outer surface of the second
substrate so as to fit within the outer surface of the second
substrate in a plan view; an auxiliary panel having a third
substrate and a fourth substrate that is larger than the third
substrate, the third substrate and the fourth substrate forming a
pair of substrates bonded together such that respective inner
surfaces thereof face each other, in which an edge portion of the
fourth substrate protrudes further out than an edge portion of the
third substrate, an inner surface at the edge portion of the fourth
substrate facing the outer surface at an edge portion of the second
substrate, the polarizing plate being sandwiched between the third
substrate and the second substrate; and an adhesive layer bonding
together the main panel and the auxiliary panel, the adhesive layer
being disposed between the polarizing plate and the third substrate
and between the second substrate and the third substrate so as to
cover a periphery of the polarizing plate.
5. The panel composite body according to claim 1, wherein the
adhesive layer is made of a photocurable adhesive.
6. A display device, comprising the panel composite body according
to claim 1 and an illumination device that radiates light to the
panel composite body.
7-10. (canceled)
11. The panel composite body according to claim 4, wherein the
adhesive layer is made of a photocurable adhesive.
12. A display device, comprising the panel composite body according
to claim 4 and an illumination device that radiates light to the
panel composite body.
Description
TECHNICAL FIELD
[0001] The present invention relates to a panel composite body, a
display device, and a manufacturing method for a panel composite
body.
BACKGROUND ART
[0002] In recent years, display devices including function panels
such as touch panels, viewing angle control panels, and parallax
barrier panels, along with liquid crystal panels that display
images and the like are known (refer to Patent Document 1, for
example). In these types of display devices, the above-mentioned
function panel as an auxiliary panel is bonded to a surface of the
liquid crystal panel as a main panel through an adhesive.
[0003] As the adhesive, in general, a photocurable (photosensitive)
adhesive is used. Such a photocurable adhesive is liquid before
being cured by being irradiated with light such as ultraviolet, and
has fluidity. When bonding together the main panel and the
auxiliary panel, this fluid adhesive is first applied to a surface
of the main panel. The auxiliary panel is stacked onto the surface
of the main panel so as to sandwich the adhesive applied in this
manner. Then, respective positions of the main panel and the
auxiliary panel are set and the adhesive is irradiated with light
such as ultraviolet light, thus bonding together the main panel and
the auxiliary panel.
[0004] If the adhesive layer between the main panel and the
auxiliary panel has an uneven thickness, then variation occurs in
the distance (gap) between the main panel and the auxiliary panel.
This sometimes causes display unevenness such as color unevenness
in the image in the main panel perceived by a user through the
auxiliary panel. Thus, in order to provide the adhesive layer with
an even thickness, while the adhesive is still fluid, the adhesive
is thinly spread between the main panel and the auxiliary panel so
as to be flat.
[0005] In general, a polarizing plate is provided on the topmost
surface of the main panel (liquid crystal panel). Thus,
specifically, the adhesive is thinly spread as described above
between the polarizing plate and the auxiliary panel. Generally,
the polarizing plate is somewhat smaller than the main body of the
main panel (liquid crystal panel), and the periphery of the
polarizing plate is to the inside of the periphery of the main
panel.
[0006] Some of the adhesive seeps towards the outside from between
the polarizing plate and the auxiliary panel. Among the adhesive
that seeps out, some of the adhesive reaches the surface of the
main body of the main panel further out than the periphery of the
polarizing plate, causing it to cover the periphery of the
polarizing plate.
[0007] The polarizing plate is easily affected by humidity, and
swells if it absorbs water (moisture) from the outside air, and
thus, the polarizing plate sometimes undergoes a change in
thickness. Swelling in the polarizing plate is sometimes a cause
for the display unevenness described above. Thus, the periphery of
the polarizing plate is covered by the adhesive.
RELATED ART DOCUMENT
Patent Document
[0008] Patent Document 1: Japanese Patent Application Laid-Open
Publication No. 2005-181410
Problems to be Solved by the Invention
[0009] If liquid adhesive seeps out from between the main panel and
the auxiliary panel as described above, then there is a problem
that depending on how much seeps out, sometimes the adhesive
reaches the display surface of the auxiliary panel or the rear
surface of the main panel. If the adhesive sticks to the display
surface of the auxiliary panel and the like, this contaminates
those portions resulting in display anomalies.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide, for a
panel composite body including a main panel and an object to be
bonded thereto, a technique to minimize seepage of an adhesive
disposed therebetween towards the outside from an edge portion of
the panel composite body.
Means for Solving the Problems
[0011] A panel composite body according to the present invention
includes: a main panel having: a larger first substrate and a
smaller second substrate that form a pair of a larger substrate and
a smaller substrate bonded together such that respective inner
surfaces thereof face each other, an edge portion of the larger
substrate protruding further out than an edge portion of the
smaller substrate; and a polarizing plate disposed on an outer
surface of the second substrate so as to fit within a plate surface
of the second substrate; a plate member sandwiching the polarizing
plate with the second substrate, the plate member protruding
further out than the edge portion of the second substrate; and an
adhesive layer bonding together the main panel and the plate
member, the adhesive layer being disposed between the polarizing
plate and the plate member and between the second substrate and the
plate member so as to cover a periphery of the polarizing
plate.
[0012] The panel composite body may further include an auxiliary
panel having the plate member and an opposite plate member bonded
thereto so as to face the plate member, the opposite plate member
being disposed between the plate member and the polarizing
plate.
[0013] In the panel composite body, the auxiliary panel may have a
smaller third substrate as the opposite plate member and a larger
fourth substrate as the plate member forming a pair of a larger
substrate and a smaller substrate bonded together such that
respective inner surfaces thereof face each other, in which an edge
portion of the larger substrate protrudes further out than an edge
portion of the smaller substrate, an edge portion of the fourth
substrate protruding further out than at least the edge portion of
the second substrate, an inner surface at the edge portion of the
fourth substrate facing an inner surface at the edge portion of the
first substrate, the polarizing plate being sandwiched between the
third substrate and the second substrate, and the adhesive layer
may bond together the main panel and the auxiliary panel, the
adhesive layer being disposed between the polarizing plate and the
third substrate and between the second substrate and the third
substrate so as to cover a periphery of the polarizing plate.
[0014] Another panel composite body according to the present
invention includes: a main panel having a pair of a first substrate
and a second substrate bonded together such that respective inner
surfaces thereof face each other, and a polarizing plate disposed
on an outer surface of the second substrate so as to fit within a
plate surface of the second substrate; an auxiliary panel having a
smaller third substrate and a larger fourth substrate that form a
pair of a larger substrate and a smaller substrate bonded together
such that respective inner surfaces thereof face each other, in
which an edge portion of the larger substrate protrudes further out
than an edge portion of the smaller substrate, an inner surface at
the edge portion of the fourth substrate facing an outer surface at
an edge portion of the second substrate, the polarizing plate being
sandwiched between the third substrate and the second substrate;
and an adhesive layer bonding together the main panel and the
auxiliary panel, the adhesive layer being disposed between the
polarizing plate and the third substrate and between the second
substrate and the third substrate so as to cover a periphery of the
polarizing plate.
[0015] In the panel composite body, it is preferable that the
adhesive layer be made of a photocurable adhesive.
[0016] A display device of the present invention includes the
aforementioned panel composite body and an illumination device that
radiates light to the panel composite body.
[0017] A manufacturing method for a panel composite body according
to the present invention includes: applying an uncured fluid
photocurable adhesive on a plate surface of a polarizing plate of a
main panel having: a larger first substrate and a smaller second
substrate that form a pair of a larger substrate and a smaller
substrate bonded together such that respective inner surfaces
thereof face each other, an edge portion of the larger substrate
protruding further out than an edge portion of the smaller
substrate; and the polarizing plate disposed on an outer surface of
the second substrate so as to fit within a plate surface of the
second substrate; stacking a plate member on the plate surface of
the polarizing plate to which the adhesive has been applied such
that the plate member protrudes further out than the edge portion
of the second substrate so as to sandwich the polarizing plate
between the plate member and the second substrate, and such that
the adhesive is pressed and spread between the plate member and the
polarizing plate; and curing the adhesive by radiating light
thereon and thereby bonding together the main panel and the plate
member.
[0018] The manufacturing method for a panel composite body may
further include an auxiliary panel having the plate member and an
opposite plate member bonded thereto so as to face the plate
member, the opposite plate member being disposed between the plate
member and the polarizing plate.
[0019] In the manufacturing method for a panel composite body, the
auxiliary panel may have a smaller third substrate as the opposite
plate member and a larger fourth substrate as the plate member that
form a pair of a larger substrate and a smaller substrate bonded
together such that respective inner surfaces thereof face each
other, an edge portion of the larger substrate protruding further
out than an edge portion of the smaller substrate, in the step of
stacking, the auxiliary panel may be stacked onto the plate surface
of the polarizing plate to which the adhesive is applied and the
adhesive is pressed and spread between the auxiliary panel and the
polarizing plate such that an edge portion of the fourth substrate
protrudes further out than at least an edge portion of the second
substrate, and an inner surface at the edge portion of the fourth
substrate and an inner surface at the edge portion of the first
substrate face each other with the polarizing plate being
sandwiched between the third substrate and the second substrate,
and in the step of curing, light may be radiated on the adhesive,
thereby curing the adhesive and bonding together the main panel and
the auxiliary panel.
[0020] Another manufacturing method for a panel composite body
according to the present invention includes: applying an uncured
fluid photocurable adhesive on a plate surface of a polarizing
plate of a main panel that has a pair of a first substrate and a
second substrate bonded together such that inner surfaces thereof
face each other, and the polarizing plate disposed on an outer
surface of the second substrate so as to fit within the plate
surface of the second substrate; stacking an auxiliary panel onto
the plate surface of the polarizing plate to which the adhesive is
applied, in which the auxiliary panel has a smaller third substrate
and a larger fourth substrate that form a pair of a larger
substrate and a smaller substrate bonded together such that
respective inner surfaces thereof face each other, an edge portion
of the larger substrate protruding further out than an edge portion
of the smaller substrate, an inner surface at the edge portion of
the fourth substrate facing an outer surface at an edge portion of
the second substrate, the polarizing plate being sandwiched between
the third substrate and the second substrate, the adhesive being
pressed and spread between the auxiliary panel and the polarizing
plate; and curing the adhesive by radiating light thereon and
thereby bonding together the main panel and the auxiliary
panel.
Effects of the Invention
[0021] According to the present invention, for a panel composite
body including a main panel and an object to be bonded thereto, a
technique to minimize seepage of an adhesive disposed therebetween
towards the outside from an edge portion of the panel composite
body can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a plan view of a liquid crystal display device of
Embodiment 1.
[0023] FIG. 2 is a cross-sectional view of the liquid crystal
display device shown in FIG. 1.
[0024] FIG. 3 is a magnified cross-sectional view of an edge
portion of a panel composite body.
[0025] FIG. 4 is a plan view of a liquid crystal panel.
[0026] FIG. 5 is a magnified cross-sectional view of an edge
portion of a panel composite body of Embodiment 2.
[0027] FIG. 6 is a magnified cross-sectional view of an edge
portion of a panel composite body of Embodiment 3.
[0028] FIG. 7 is a magnified cross-sectional view of an edge
portion of a panel composite body of Embodiment 4.
[0029] FIG. 8 is a plan view of a liquid crystal panel provided in
the panel composite body of Embodiment 4.
DETAILED DESCRIPTION OF EMBODIMENTS
Embodiment 1
[0030] Embodiment 1 of the present invention will be explained
below with reference to FIGS. 1 to 4. In the present embodiment, a
liquid crystal display device (display device) 10 will be described
as an example. FIG. 1 is a plan view of the liquid crystal display
device 10 in Embodiment 1, and FIG. 2 is a cross-sectional view of
the liquid crystal display device 10 shown in FIG. 1. In the
respective drawings, an X axis, a Y axis, and a Z axis are shown as
necessary.
[0031] (Liquid Crystal Display Device)
[0032] As shown in FIG. 1, the liquid crystal display device 10 has
a rectangular shape. FIG. 1 shows the liquid crystal display device
10 as viewed from the display surface side. FIG. 2 schematically
shows the cross-sectional structure of the liquid crystal display
device 10 along the widthwise direction (the line A-A shown in FIG.
1). The liquid crystal display device 10 of the present embodiment,
as shown in FIG. 2, includes a panel composite body 1, an
illumination device 13, a bezel 14, and a housing member 15.
[0033] The panel composite body 1 includes a liquid crystal panel
(main panel) 11 that displays an image on a display surface on the
front thereof, and a parallax barrier panel (auxiliary panel) 12
disposed on the front of the liquid crystal panel 11 to allow a
user to perceive an image displayed on the display surface of the
liquid crystal panel 11 as a stereoscopic image (three-dimensional
image). The liquid crystal panel 11 and the parallax barrier panel
12 are substantially rectangular when viewed from the front
(display surface side), and are set at substantially the same size.
However, as will be described below, the liquid crystal panel 11 is
set to be slightly larger than the parallax barrier panel 12. Also,
the liquid crystal panel 11 and the parallax barrier panel 12 are
bonded to each other through an adhesive layer.
[0034] The illumination device 13 is disposed on the rear side of
the panel composite body 1. The illumination device 13 is housed in
the box-shaped housing member 15, and the panel composite body is
placed on the periphery of the housing member 15. The illumination
device 13 is configured so as to radiate light towards the rear
surface of the panel composite body 1. The frame-shaped bezel 14
covers the periphery of the panel composite body 1 (refer to FIG.
1).
[0035] With reference to FIGS. 3 and 4, the panel composite body 1
and the respective panels 11 and 12 constituting the panel
composite body 1 will be described in detail. FIG. 3 is a magnified
cross-sectional view of an edge portion of the panel composite body
1, and FIG. 4 is a plan view of the liquid crystal panel 11. In
FIG. 3, the parallax barrier panel 12 is shown towards the top, and
the liquid crystal panel 11 is shown towards the bottom.
[0036] The liquid crystal panel 11 mainly includes a liquid crystal
layer 113, a frame-shaped sealing member 114 that surrounds the
liquid crystal layer 113, and a pair of transparent substrates 111
and 112, which sandwich the liquid crystal layer 113 and the
sealing member 114 and have inner surfaces 111b and 112b that face
each other. One of the substrates 111 is a thin film transistor
(hereinafter, TFT) array substrate (first substrate) and the other
substrate 112 is a color filter (hereinafter, CF) substrate (second
substrate).
[0037] While the substrate 111 and the substrate 112 both have
rectangular shapes, the substrate 111 is slightly larger than the
substrate 112 (refer to FIG. 4). In other words, of the pair of
substrates 111 and 112, the substrate 111 is larger and the
substrate 112 is smaller. Also, as shown in FIG. 3 and the like,
the substrates 111 and 112 are bonded to each other such that an
edge portion 111a of the substrate 111 protrudes further out than
an edge portion 112a of the substrate 112. In other words, the edge
portion of the liquid crystal panel 11 is formed in a step shape by
the edge portion 111a of the substrate 111 and the edge portion
112a of the substrate 112. The edge portions 111a and 112a of the
respective substrates 111 and 112 protrude further out than the
sealing member 114. The thickness of the respective substrates 111
and 112 in the present embodiment is approximately 0.25 mm.
[0038] As shown in FIG. 3, a polarizing plate 115 is bonded to an
outer surface 112c of the substrate 112, and a polarizing plate 116
is bonded to an outer surface 111c of the substrate 111. The shape
of the polarizing plate 115 is a rectangular shape as shown in FIG.
4. The polarizing plate 115 is slightly smaller in size than the
substrate 112. The polarizing plate 115 is bonded to the surface
112c (plate surface on the front) such that the periphery of the
polarizing plate 115 fits within the surface 112c of the substrate
112. The thickness of the polarizing plate 115 of the present
embodiment is approximately 0.12 mm.
[0039] The polarizing plate 115 is made by sandwiching a
film-shaped polarizer between protective films made of triacetyl
cellulose or the like, for example. The polarizer is made by
performing uniaxial stretching on a polyvinyl alcohol film dyed
with iodine, for example. In another embodiment, another film such
as a phase contrast film may be stacked on the polarizing plate
115.
[0040] The polarizing plate 116 has a rectangular shape, as in the
polarizing plate 115, and has the same size as the polarizing plate
115. The size of the polarizing plate 116 is slightly smaller than
the substrate 111. The polarizing plate 116 is also bonded to the
surface 111c (plate surface on the front) such that the periphery
of the polarizing plate 116 fits within the surface 111c of the
substrate 111. The polarizing plate 116 and the polarizing plate
115 face each other. The polarizing plate 116 also has a basic
structure similar to the polarizing plate 115.
[0041] As shown in FIG. 4, the liquid crystal panel 11 has a
terminal pattern 16 that is connected to ends of wiring lines drawn
to the outside of the sealing member 114, the terminal pattern 16
being formed on an inner surface of the edge portion of the TFT
array substrate 111. An IC (integrated circuit) chip 17 and an FPC
(flexible printed circuit) 18 are mounted so as to be electrically
connected to the terminal pattern 16.
[0042] The parallax barrier panel 12 mainly includes a liquid
crystal layer 123, a frame-shaped sealing member 124 surrounding
the liquid crystal layer 123, and a pair of transparent substrates
121 and 122 having inner surfaces 121b and 122b that face each
other across the liquid crystal layer 123 and the sealing member
124. The substrate (third substrate) 121 and the substrate (fourth
substrate) 122 are both rectangular and the same size. The
substrates 121 and 122 are set such that an edge portion 121a of
the substrate 121 and an edge portion 122a of the substrate 122 are
in the same position.
[0043] An adhesive layer 21 is disposed between the liquid crystal
panel 11 and the parallax barrier panel 12. The liquid crystal
panel 11 and the parallax barrier panel 12 are stacked one on top
of the other, bonded to each other through the adhesive layer 21.
This adhesive layer 21 is made of a photocurable adhesive having a
photocurable (photosensitive) resin such as an ultraviolet curable
resin as its main component, for example.
[0044] As shown in FIG. 3, the positional relation of the liquid
crystal panel 11 and the parallax barrier panel 12 stacked across
the liquid crystal layer 21 is such that the respective sealing
members 114 and 124 match each other in position in the direction
in which panels are stacked. In this state, the edge portions 121a
and 122a of the respective substrates 121 and 122 of the parallax
barrier panel 12 protrude further to the outside than the edge
portion of the CF substrate 112a of the liquid crystal panel 11. An
outer surface 121c at the edge portion 121a of the substrate 121
faces the inner surface 111b at the edge portion 111a of the TFT
array substrate 111. The inner surface 122b at the edge portion
122a of the substrate 122 also faces the inner surface 111b across
the substrate 121.
[0045] With the liquid crystal panel 11 and the parallax barrier
panel 12 having such a positional relation, a gap S1 surrounding
the periphery of the polarizing plate 115 is formed between the CF
substrate 112 of the liquid crystal panel 11 and the substrate 121
of the parallax barrier panel 12. Also, a gap S2 surrounding the
periphery of the CF substrate 112 is formed between the TFT array
substrate 111 of the liquid crystal panel 11 and the substrate 121.
The gap S2 is positioned outside of the gap S1 so as to surround
it, and is connected to the gap S1. The width of the gap S2 in the
direction in which panels are stacked is greater than the width of
the gap 1 in the direction in which panels are stacked.
[0046] Also, as shown in FIG. 3, the adhesive layer 21 is mainly
disposed between the polarizing plate 115 of the liquid crystal
panel 11 and the substrate 121 of the parallax barrier panel 12. In
other words, the adhesive layer 21 is formed so as to cover the
plate surface of the polarizing plate 115. The thickness of the
adhesive layer 21 in this portion is approximately 0.05 mm. Also, a
portion of the adhesive layer 21 fills the gap S1 so as to surround
the periphery of the polarizing plate 115 disposed on the outer
surface 112c of the CF substrate 112. Some of the adhesive layer 21
also fills some of the gap S2 described above. However, the
adhesive layer 21 does not seep to the outside of the gap Si and
reach the outer surface 122c of the substrate 122 of the parallax
barrier panel 11 or the outer surface 111c of the TFF array
substrate 111 of the liquid crystal panel 11.
[0047] Such an adhesive layer 21 bonds together the liquid crystal
panel 11 and the parallax barrier panel 12 and has the function of
putting together one panel composite body 1. Having the adhesive
layer 21 surround the periphery of the polarizing plate 115 also
serves the function of protecting the polarizing plate 115 so that
it does not absorb water (moisture) from the outside air and swell
(expand). The polarizing plate 115 is sealed by the adhesive layer
21 between the CF substrate 112 and the substrate 121.
[0048] Here, a method of manufacturing the panel composite body 1
including the adhesive layer 21 will be described. First, on the
plate surface of the polarizing plate 115 included in the liquid
crystal panel 11, a prescribed amount of uncured liquid
photocurable (ultraviolet curable) adhesive is applied (step of
application).
[0049] As a method to apply the adhesive onto the plate surface of
the polarizing plate 115, a known adhesive application method is
used. For example, as shown in FIG. 4, a prescribed discharge
nozzle (not shown) positioned above the plate surface of the
rectangular polarizing plate 115 may form a plurality of linear
coat films R made of the adhesive on the plate surface by having
the discharge nozzle discharge the adhesive while moving in the
widthwise direction. The coat films R are formed over the entire
plate surface of the polarizing plate 115. However, at the stage in
which the adhesive is applied onto the plate surface of the
polarizing plate 115, there may be portions (gaps) where the coat R
is not formed between adjacent linear coat films R. As will be
described layer, the coat film R will eventually be spread evenly
over the plate surface of the polarizing plate 115 to form an
adhesive layer that covers the entire plate surface.
[0050] After forming the coat films R on the plate surface of the
polarizing plate 115, the parallax barrier panel 12 is placed
thereon (step of stacking). The parallax barrier panel 12 is placed
on the coat films R such that the substrate 121 thereof comes
directly into contact with the coat films R. In other words, the
coat films R made of the adhesive are sandwiched between the plate
surface of the polarizing plate 115 and the outer surface 121c of
the substrate 121.
[0051] The parallax barrier panel 12 is pressed onto the plate
surface of the polarizing plate 115 with a certain amount of force.
Then, the coat films R made of the adhesive, pressed between the
plate surface of the polarizing plate 115 and the outer surface
121c of the substrate 121, spread thinly so as to cover the plate
surface of the polarizing plate 115. At this time, the coat film R
formed on the plate surface in the periphery of the polarizing
plate 115 spreads out from the periphery of the polarizing plate
15. The state in which a portion of the coat film R seeps outward
from the periphery of the polarizing plate 115 is shown
schematically with arrows in FIG. 4. Then, some of the adhesive in
the coat film R enters the gap Si shown in FIG. 3. Then, the
periphery of the polarizing plate 115 is covered by the adhesive.
Some of the adhesive that has entered the gap S1 may go beyond the
edge portion 112a of the CF substrate 112 and enter the gap S2. The
positional relation between the liquid crystal panel 11 and the
parallax barrier panel 12 is appropriately adjusted before the
adhesive is cured.
[0052] Then, ultraviolet light is radiated onto the adhesive, thus
curing the adhesive (step of curing). As the adhesive is cured, it
becomes the adhesive layer 21 shown in FIG. 3, and thus, the liquid
crystal panel 11 and the parallax barrier panel 12 are bonded
together. Also, the periphery of the polarizing plate 115 is sealed
by the adhesive layer 21. The light such as ultraviolet light is
radiated towards the adhesive from outside the respective panels 11
and 12 so as to pass therethrough, for example. With the process
described above, the liquid crystal panel 11 and the parallax
barrier panel 12 are bonded together, thus forming the panel
composite body 1.
[0053] However, if the total amount of liquid adhesive applied on
the plate surface of the polarizing plate 115 is small, then the
adhesive does not reach the edge portion of the plate surface, and
the adhesion between the liquid crystal panel 11 and the parallax
barrier panel 12 is insufficient. Also, even if the adhesion
between the liquid crystal panel 11 and the parallax barrier panel
12 were sufficient, depending on the total amount of adhesive
applied, sometimes the periphery of the polarizing plate 115 is
exposed. Thus, depending on the total amount of adhesive applied,
the amount of adhesive seeping out from between the polarizing
plate 115 and the substrate 121 is insufficient.
[0054] Thus, in order to reliably cover the periphery of the
polarizing plate 115 with the adhesive, in general, the total
amount of adhesive applied to the plate surface of the polarizing
plate 115 is set to be relatively large but within a range in which
the adhesive does not seep out from the edge portion of the panel
composite body 1.
[0055] In the present embodiment, a gap S1 where the adhesive for
covering the periphery of the polarizing plate 115 is held is
formed between the CF substrate 112 of the liquid crystal panel 11
and the substrate 121 of the parallax barrier panel 12, and the gap
S2 where the adhesive that seeps out from the gap S1 can be held is
present outside of the gap S1. Thus, it is easy to set the total
amount of resin applied in advance on the plate surface of the
polarizing plate 115 to a relatively large amount. In other words,
the allowable range in total amount of the adhesive applied on the
plate surface of the polarizing plate 115 is wide as a result of
providing the gap S2. Thus, even if the concentration, viscosity,
or the like of the adhesive changes due to the usage environment of
the adhesive (humidity, temperature, and the like) changing, the
amount of adhesive applied can be controlled with ease.
[0056] Thus, according to the panel composite body 1 and the
manufacturing method therefor of the present embodiment, a
situation in which the liquid adhesive reaches the front (outer
surface 122c of the substrate 122) of the parallax barrier panel 12
or the rear (outer surface 111c of the TFT array substrate 11) of
the liquid crystal panel 11, bonds to those surfaces, and causes
contamination there, is mitigated while allowing the liquid crystal
panel 11 and the parallax barrier panel 12 to be bonded together
well. In other words, according to the panel composite body and the
manufacturing method therefor of the present embodiment, it is
possible to mitigate such contamination while having the liquid
crystal panel 11 and the parallax barrier panel 12 bonded together
sufficiently, and such that the adhesive is applied to the
periphery of the polarizing plate 115 without any gaps.
Embodiment 2
[0057] Next, Embodiment 2 of the present invention will be
explained below with reference to FIG. 5. In the respective
embodiments below, parts that are the same as those in Embodiment 1
will be assigned the same reference characters as Embodiment 1, and
detailed descriptions thereof will be omitted. FIG. 5 is a
magnified cross-sectional view of an edge portion of a panel
composite body 1A of Embodiment 2. The basic configuration of the
panel composite body 1A of the present embodiment is similar to
that of Embodiment 1. Specifically, the liquid crystal panel 11 is
the same as that of Embodiment 1. As for the parallax barrier panel
12A also, the basic configuration is similar to that of Embodiment
1. However, a substrate 121A included in the parallax barrier panel
12A is smaller than that of Embodiment 1, and an edge portion 122a
thereof is disposed further inside (towards the sealing member 124)
than that of Embodiment 1. In other words, the edge portion 122a of
the substrate 122 of the parallax barrier panel 12A protrudes
further out than an edge portion 121Aa of the substrate 121A, and
an inner surface 122b at the edge portion 122a faces an inner
surface 111b at an edge portion 111a of the TFT array substrate 111
included in the liquid crystal panel 11. In other words, the edge
portion of the parallax barrier panel 12 is also formed into steps
as in the edge portion of the liquid crystal panel 11.
[0058] The position of the edge portion 121Aa of the substrate 121A
included in the parallax barrier panel 12A is set to be the same as
the position of the edge portion 112a of the CF substrate 112
included in the liquid crystal panel 11.
[0059] In the panel composite body 1A of the present embodiment
also, a gap S1A surrounding the periphery of a polarizing plate 151
is formed between an outer surface 112c of the substrate 112 and an
outer surface 121Ac of the substrate 121A. Furthermore, a gap S2A
is also formed between the inner surface 111b of the substrate 111
and the inner surface 122b of the substrate 122. In the present
embodiment, the width of the gap S2A in the direction in which the
panels are stacked is greater than the width of the gap S2 of the
Embodiment 1, and the amount of adhesive 21A seeping out from
between the substrate 112 and the substrate 121 that can be held at
the gap S2A is greater than the gap S2 of Embodiment 1. In other
words, in manufacturing the panel composite body 1A, when bonding
together the liquid crystal panel 11 and the parallax barrier panel
12A, the allowable range of the total amount of adhesive applied on
the plate surface of the polarizing plate 115 is wider than in
Embodiment 1.
[0060] Thus, according to the present embodiment, a situation in
which the liquid adhesive reaches the front (outer surface 122c of
the substrate 122) of the parallax barrier panel 12A or the rear
(outer surface 111c of the TFT array substrate 111) of the liquid
crystal panel 11, bonds to those surfaces, and causes contamination
there is mitigated, while allowing the liquid crystal panel 11 and
the parallax barrier panel 12A to be bonded together well. In other
words, according to the panel composite body 1A and the
manufacturing method therefor of the present embodiment, it is
possible to mitigate such contamination while having the liquid
crystal panel 11 and the parallax barrier panel 12A bonded together
sufficiently, and such that the adhesive is applied to the
periphery of the polarizing plate 115 without any gaps.
Embodiment 3
[0061] Next, Embodiment 3 of the present invention will be
explained below with reference to FIG. 6. FIG. 6 is a magnified
cross-sectional view of an edge portion of a panel composite body
1B of Embodiment 3. The liquid crystal panel 11 included in the
panel composite body 1B of the present embodiment is similar to
that of Embodiment 1. However, in the present embodiment, one
protective plate 122B, instead of an auxiliary panel, is bonded to
the liquid crystal panel 11. The protective plate 122B is for
protecting the display surface of the liquid crystal panel 11, and
is a transparent plate-shaped member. The protective plate 122B has
a rectangular shape, and an edge portion 122Ba thereof is set so as
to protrude further out than an edge portion 112a of a CF substrate
112 of the liquid crystal panel 11. An inner surface 122Bb at the
edge portion 122Ba thereof faces the inner surface 111b at the edge
portion 111a of the TFT array substrate 111. The inner surface
122Bb of the protective plate 122B also faces the outer surface
112c of the CF substrate 112.
[0062] In the panel composite body 1B of the present embodiment
also, the outer surface 112c of the substrate 112 and the inner
surface 122Bb of the protective plate 122B have a gap S1B
therebetween that surrounds the periphery of the polarizing plate
151. Furthermore, a gap S2B is also formed between the inner
surface 111b of the substrate 111 and the inner surface 122Bb of
the substrate 122B. The liquid crystal panel 11 and the protective
plate 122B are bonded to each other through an adhesive layer 21B.
In the manner, the object to be attached to the liquid crystal
panel 11 may be one protective plate 122B instead of a panel made
by stacking a plurality of substrates (plates) as in Embodiment 1
and the like.
[0063] In the present embodiment also, a situation in which the
liquid adhesive reaches the front (outer surface 122Bc) of the
protective plate 122B or the rear (outer surface 111c of the TFT
array substrate 111) of the liquid crystal panel 11, bonds to those
surfaces, and causes contamination there is mitigated, while
allowing the liquid crystal panel 11 and the protective plate 122B
to be bonded together well. In other words, according to the panel
composite body 1B and the manufacturing method therefor of the
present embodiment, it is possible to mitigate such contamination
while having the liquid crystal panel 11 and the protective plate
122B bonded together sufficiently, and such that the adhesive is
applied to the periphery of the polarizing plate 115 without any
gaps.
Embodiment 4
[0064] Next, with reference to FIGS. 7 and 8, Embodiment 4 of the
present invention will be explained. FIG. 7 is a magnified
cross-sectional view of an edge portion of a panel composite body
1C of Embodiment 4, and FIG. 8 is a plan view of a liquid crystal
panel 1C included in the panel composite body 1C of Embodiment 4.
The parallax barrier panel 12 included in the panel composite body
1C of the present embodiment is similar to that of Embodiment 2. By
contrast, while the basic configuration of the liquid crystal panel
1C is similar to those of Embodiment 2 and the like, the CF
substrate 112C is set to be larger (smaller) than those of
Embodiment 2 and the like. The position of an edge portion 112Ca of
the CF substrate 112C is set to be the same as an edge portion 111a
of the TFT array substrate 111. As shown in FIG. 8, the length of
the TFT array substrate 111 in the lengthwise direction is greater
than the length of the CF substrate 112C in the lengthwise
direction, and the portion where an IC chip 16 and the like are
mounted is exposed from the CF substrate 112C. However, the length
of the TFT array substrate 111 in the widthwise direction is set to
be the same as the length of the CF substrate 112C in the widthwise
direction.
[0065] In the panel composite body 1C, the inner surface 122b of
the edge portion 122a of the substrate 122 is opposite to the outer
surface 122Cc of the edge portion 112Ca of the CF substrate 112C.
Also, the edge portion 121Aa of the edge portion 121A of the
substrate 121A is disposed further inside than the edge portion
122a of the substrate 122, but the outer surface 121Ac thereof
faces the outer surface 122Cc of the CF substrate 112C, in a
similar manner to the substrate 122. A gap S1C is formed between
the outer surface 112Cc of the substrate 112C and the outer surface
121Ac of the substrate 121A, and a gap S2C is formed between the
outer surface 112Cc of the substrate 112C and the inner surface
122a of the substrate 122. The liquid crystal panel 11C and the
parallax barrier panel 12A are bonded together by the adhesive
layer 21C. In the above-mentioned manner, the respective gaps S1C
and S2C described above may be formed by having the edge portion of
the parallax barrier panel 12A as the auxiliary panel be formed
into steps instead of the liquid crystal panel 11, which is the
main panel.
[0066] According to the present embodiment also, a situation in
which the liquid adhesive reaches the front (outer surface 122c) of
the parallax barrier panel 12A or the rear (outer surface 111c of
the TFT array substrate 111) of the liquid crystal panel 11C, bonds
to those surfaces, and causes contamination there is mitigated,
while allowing the liquid crystal panel 11C and the parallax
barrier panel 12A to be bonded together well. In other words,
according to a panel composite body 1C and a manufacturing method
therefor of the present embodiment, such contamination is mitigated
while ensuring sufficient adhesion between the liquid crystal panel
11C and the parallax barrier panel 12A. Additionally, the adhesive
in the periphery of the polarizing plate 115 is spread throughout
without any gaps.
Other Embodiments
[0067] The present invention is not limited to the embodiments
shown in the drawings and described above, and the following
embodiments are also included in the technical scope of the present
invention, for example.
[0068] (1) In the embodiments above, the object bonded to the
liquid crystal panel, which is the main panel, was a parallax
barrier panel, which is an auxiliary panel, or a protective plate,
but in other embodiments, other objects may be attached. For
example, various types of panels such as a viewing angle control
panel, a touch panel, and other types of panels for image display
can be used as an auxiliary panel, and there is no special
limitation.
[0069] (2) In the embodiments above, the auxiliary panel (parallax
barrier panel) had a configuration in which one polarizing plate
was bonded to one outer surface (display surface side) thereof, but
in other embodiments, a configuration may be used in which a pair
of polarizing plates is bonded to the respective outer surfaces of
the auxiliary panel.
[0070] (3) In the embodiments above, the photocurable adhesive is
cured by ultraviolet light, but in other embodiments, the adhesive
may be cured by other types of light such as visible or
infrared.
[0071] (4) In the embodiments above, a photocurable resin was the
main component of the adhesive, but in other embodiments, a heat
curable resin may be the main component, for example.
[0072] (5) In the embodiments above, the panel composite body had a
configuration in which one auxiliary panel was stacked onto one
main panel through an adhesive layer, but in other embodiments, a
configuration may be used in which two or more auxiliary panels are
stacked on one main panel through respective adhesive layers, for
example. Also, a configuration may be used in which one auxiliary
panel is stacked on one main panel through an adhesive layer, and
on top of the auxiliary panel, a plate member such as a protective
plate is stacked through another adhesive layer.
[0073] (6) In the embodiments above, the main panel included in the
panel composite body was slightly larger than the auxiliary panel,
but as long as the object of the present invention is achieved, in
other embodiments, the main panel and the auxiliary panel may be
set to the same size, or the auxiliary panel may be set to be
larger than the main panel.
Description of Reference Characters
[0074] 1, 1A, 1B, 1C panel composite body
[0075] 10 liquid crystal display device (display device)
[0076] 11, 11A, 11C liquid crystal panel (main panel)
[0077] 12, 12A parallax barrier panel (auxiliary panel)
[0078] 21, 21A, 21B, 21C adhesive layer
[0079] 111 TFT array substrate (first substrate)
[0080] 112 CF substrate (second substrate)
[0081] 113 liquid crystal layer
[0082] 115 polarizing plate
[0083] 121 substrate (third substrate, opposite plate member)
[0084] 122 substrate (fourth substrate, plate member)
[0085] 123 liquid crystal layer
[0086] S1, S1A, S1B, S1C gap
[0087] S2, S2A, S2B, S2C gap
* * * * *